copyright © scott bader co ltd scott bader co ltd solutions for composites applications

Copyright © Scott Bader Co Ltd

Scott Bader Co LtdSolutions for composites Applications

www.scottbader.com


Scott Bader Ltd

• Leading international manufacturer of polyester and alkyd resins, gelcoats and polymers

• Materials are used in a range products• Offices and manufacturing plants across the globe


An International Company

Wollaston, England • Falkenberg, Sweden Amiens & Paris, France• Barcelona, Spain• Liberec, Czech Rep Zagreb, Croatia. Dubai, UAE Hammarsdale, S. Africa • Cleveland Ohio, USA• Agents & Licencees in: Asia, Australia,

New Zealand and South America.

Indicates manufacturing plant site.• Indicates sales & distribution operation.


Scott Bader History in 60 secs.

• Founded between the wars by Swiss National• Moved to Wollaston in 1940• Owner and his family put shares into Trust for the

Employees in 1950’s• Operated with Worker Director’s since then• Grown through acquisition• Large amounts of profits given to charities


Project Objective

• To replace separate legacy ERP systems at all Scott Bader sites.– AS400, PC based, Ledgers only – every site different!

• Deliver Single Best Practice method of operating– We make the same products so why not work the same

• Introduce centralised services.• Enable Multi site co-ordination

– Reactor Capacity, Materials, Orders


Selection Process

• Having identified our objectives we ran a fairly standard selection process– Request for information to many vendors– Identified top 6 approx. to receive formal ITT– From ITT responses top 4 gave workshops– From Workshops selected top 2– Details reviewed with 2 to identify preferred choice.


Movex

• One of 1st UK Java sites• Version 12.5 SP15• AS400 platform• Minimal Modifications

– Mostly linked to data streams

• Currently 200+ Users set to grow as roll out continues


Modules used – business process

• Finance, Planning, Purchasing, Sales Order Management, Production, Logistics, PDM, Forecasting.

• Single global solution enabling shared best practice and centralised services.


History Phase 1

Kick-Off Feb. 2003

Original Date for Implementation in France Jan 2004

Movex Implementation in France April 2005

Issues – identified Oct 2005

Project Audit Nov 2005

Recommendations Applied Jan 2006

Full Time Programme Director appointed mid-Jan 2006


Issues Phase 1

× Limited sponsorship and ownership within organisation

× Project seen as an IT Project rather than a Change Programme

× Project managed part-time by IT Manager

× Few people with knowledge of ERP systems & implementation experience

× Fixed Price Contract with Intentia

× Limited continuity with Consultants

× Timescale unrealistic – project very late and not likely to finish within budget

× Lack of integrated training programme (Navigation/Process/Detail)

× Lack of Training, Benefits Realisation, Communications Streams

× France not yet closed out (180 issues) – goal close out asap!


What was it like in April 2005

• A working Movex implementation in France– Has not stopped– Printed invoices on day 1 and manufacturing documents,

e-mailed PO’s• Some training outstanding – cultural, language

– and video does not work!• Some Issues

– Software and Data• A very tired team

– It took us 2 years


Restructure of Project

• Pre 2006 worked exclusively with Lawson (Intentia)• Post Go-Live at Pilot site an independent audit was

carried out.– Key Findings

• Separate project from IT by external Programme Director

• Need for full time consultancy

• Use dedicate consultants backed by Lawson Technical Specialist.

• Improve Training

• More rigorous Testing Process


Actions Phase 2

Sponsorship by CEO

Programme underlined as a Business Change Programme

Programme managed full-time contract Programme Director.

Internal knowledge of ERP systems/implementation bolstered by consultants

Intentia usage is targeted – data migration, technical consultancy

Right-sized team of consultants assigned full-time - continuity

Revised Budget and Timescale Estimates realistic

Integrated training programme (Navigation/Process/Detail) created

Training, Benefits Realisation, Communications Streams

Close France Implementation Out – based on Success Criteria by 17/03/2006


Before and After

• Steering Committee– Joint with Supplier

• Project Manager– IT Manager P/T

• Consultants– P/T Supplier

• Project Team– F/T and P/T

• Steering Committee– Scott Bader only, MD lead

• Project Manager– Full Time non IT

• Consultants– Full Time independent

• Project Team– F/T and P/T


Phase 2 Set Principles

• Right First Time, On-Time, Under Budget

• Right Sized with Internal, totalamber & Intentia (three-way)

• Full-time Dedicated Resource managed by Programme Director

• Experienced Consultants

• Fill Gaps in Internal Knowledge and Availability

• Set Vision, Mission and Values for Team

• Complete by end 1Q2007


Noticeable Changes

• CRP’s more rigorous• Stopped working in silo’s• More frequent communications• Improved training

– Produced our own suite of materials• In multiple languages

• Kept to the plan• It’s now important and critical


Roadmap Phase 2 - Target Milestones

France Implementation Closed-Out Achieved 17th March 2006

Approval of Programme Achieved 23rd March 2006

Requirements Blueprint Delivered Achieved 30th April 2006

Configuration/Modifications Complete Achieved 15th July 2006

Training Start Achieved 31st July 2006

UK Pre-CRP & CRP Complete Achieved 19th September 2006

UK Full Scale Test Complete Achieved 27th October 2006

UK Go-Live Achieved 4th December 2006

European Distribution Sites Go-Live Achieved 5th February 2007

Croatia Go-Live Achieved 2nd April 2007


Phase 2 RoadmapIn

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StartJan 2006

StartApril 2006

StartJuly 2006

StartOct 2006

StartApril 2007

06Q1 06Q2 06Q3 07Q1

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GroupBoardGroupBoard

ExecutiveBoard

ExecutiveBoard

Communications to Divisions, Boards, Staff and Stakeholders

Integrated comms plan

Q1 DashboardQ1 Dashboard Q2 DashboardQ2 Dashboard Q3 DashboardQ3 Dashboard

Develop Programme Budget

Finalise BudgetFinalise Budget

Recruit Core Team

Assign BPOs/KUs

Assign Cromos Team

Go LiveEuro Dist

Go LiveUK

Go LiveFranceGo LiveFrance

Data Mapping and Migration UK

Chro’Mapping/Migration

Familiarisation of UK/Chromos/Euo Deliverables

Gap Analysis

UK End to End Test

UK Conf.Room Pilot

UK/Chromos/Euro Modifications

Chromos Re-Validation

BuildUK FST

Chromos CRP E2E FST

Bus. ProcsApproved

Bus. ProcsApproved

Data inUK CRP

Data inUK CRP

CRPComplete

CRPComplete

Bus. ProcsCommunicatedBus. Procs

CommunicatedUK F S TCompleteUK F S TComplete

Data inChro’ CRP

Data inChro’ CRP

UK FullyOperationalUK FullyOperational

Chro’ Infrastructure Upgrade

Decommissioning UK/Chromos

Detailed Planning DetailedProg’ PlanDetailedProg’ Plan

UK Process Training

UK Detailed TrainingTraining

PlanTraining

Plan

France Process Refresh

Euro/Chro’Process Training

Euro/Chro’Detailed Training

UK Surgeries / Workshops

Design/Build Training

UK Document and Interface Builds

Chro’ Document Interface Builds

Help DeskSupport Help DeskSupport

Scope Intentia Involvement

Roadmap Milestone Review

Roadmap Milestone Review

EMP Action DayEMP Action Day EMP Action DayEMP Action Day

Develop Dashboards

PIRPlan

AgreedAudit Plan

GovernanceModel

PlanningReview

PlanningReview

RoadshowsRoadshows

UK DataTake-On

Post Go-Live Support UK/Chromos

Support of Business Training`

UK Data Cleanse

UK Cut-Over

StartJan 200706Q4

Q4 DashboardQ4 Dashboard

Cut-Over

BusinessBlueprintBusinessBlueprint

Benefits Realisation: Tracking and Delivery

Awareness Training

Kick-off

QuestionnairesCompleteQuestionnairesComplete

DesignReviewDesignReview

CRP ReviewCRP Review

Data MigrationReviewData MigrationReview

Go/No-GoReview

Go/No-GoReview


Go LiveChromos

Euro.DistCut-Over

UK StockCheck

UK StockCheck

Euro-SalesCRP E2E FST



Governance - Programme Governance Structure

Group Board

Executive

Programme Steering Committee

Andy Forrester

Phillip Bruce

Louise Brown Jeff Legg

Jean-Marc Bain Mark Griffin

Programme Executive

Sales//DistributionForecastingConsultant

Louise Brown

Jeff LeggTraining ManagerMark Griffin

Manuf/PDMForecastingConsultant

Finance/PurchasingConsultant

Agenda Weekly

• Plan vs. Actuals• Milestones• Risks and Issues• Stream Review

Agenda Monthly

• Plan vs. Actuals• Milestones• Financials• Risks and Issues

Agenda as arranged

• EMP• European Movex Programme

Business Process Teams

Louise Brown

ProgrammeTeam

Mark Griffin

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Benefits Tracking

1. Benefits Logged on Benefits Tracker

2. 100+ Tangible/Intangible Benefits Identified

3. Initial Value of £xxxk per annum identified

4. Benefits targeted at 50% per annum

5. Benefits owned by Executive Directors

6. More Benefits Recognised, Refined, Logged and Tracked through Programme

7. Benefits Analysis across Europe.

8. Benefits Delivery will be Tracked to Realisation

9. Full Programme Payback with 2-4 years


Summary:

Audit Lessons Learnt

France Phase Close-Out

Ownership (CEO) and Accountability (Prog Dir)

Communications and Training Plans in place

Realistic Right-sized Roadmap & Resource Plan

Governance Model in place

Benefits Realisation in place

Issues & Risks Logged and Mitigated

Enabled success in Europe High

Resulting in complete Global Roll-out (South Africa, USA, & Middle East) by H2 2008

copyright © scott bader co ltd scott bader co ltd solutions for composites applications

Documents

scott bader history

manufacturing plant

scott bader sites

pilot site

site different

issues phase

project auditnov

working movex implementation